Coated footwear and methods for making and using the same

ABSTRACT

Coated footwear and methods for making and using the same. An outer surface of a fabric layer conforming closely to the top, sides, bottom and individual toes of a foot is coated with a material in the areas where the fabric layer conforms closely to the sides, bottom and individual toes of the foot. The fabric layer can be elastic, breathable, ultraviolet light inhibiting, and/or chosen from the class of materials including supplex, spandex, nylon, and nylon/cotton blend. The coating can be textured, chosen from one or more of the class of materials including latex, nitrile, and polyurethane and/or including a chemical agent to insure adhesion of the coating to the outer surface of the fabric layer. The footwear can be made by immersing the fabric layer in a container filled with the coating material. Also, if desired, a second coating can be adhered over the first coating.

TECHNICAL FIELD

The present invention relates to footwear and methods for making andusing the same, and more particularly, to footwear and methods formaking and using the same.

BACKGROUND OF THE INVENTION

Many types of footwear are known and have been employed since timeimmemorial. However, people who work or recreate out-of-doors have nothad footwear available which would protect their feet from the heat androughness of the supporting ground or pavement while providing tactilefeel and allowing the components of the foot freedom of movement.

Footwear intended for use in a casual or recreational environment existsin many forms. Of course, socks of woven or knitted construction are animportant form of footwear. Conventional woven or knitted socks offerlittle or no protection against the elements.

It is therefore an object of the present invention to provide animproved work or recreation shoe that provides protection of a foot fromthe heat of the ground or pavement.

It is a further object of the present invention to provide an improvedwork or recreation footwear that provides protection of a foot fromrough surfaces including ground and pavement, swimming pool bottoms,beach shores and workout areas.

It is another object of the present invention to provide an improvedwork or recreation footwear capable of improved tactile feel forheightened physical performance, including but not limited to a texturedcoating that helps retain traction on wet or slick surfaces.

It is yet another object of the invention to provide improved work andrecreation footwear that insulates the skin from direct contact withunsanitary surface, thus limiting risk of Athlete's Foot and othercontagious conditions.

An advantage of the present invention is that it can provide footprotection for a user in various environments while the user is wearingit.

SUMMARY OF THE INVENTION

According to one aspect, the invention is a footwear for a foot on ahuman leg having an ankle. The footwear includes a fabric layer and acoating. The fabric layer has an inner surface and a corresponding outersurface. The inner surface conforms closely to the top, sides, bottomand individual toes of the foot. The coating is adhered to sections ofthe outer surface of the fabric layer. The sections correspond to theportions of the inner surface of the fabric layer that conform closelyto the sides, bottom and individual toes of the foot.

According to a second aspect, the invention is a method for making afootwear for a foot on a human leg having an ankle. The method includesthe step of a) forming a fabric layer having an inner surface and acorresponding outer surface, where the inner surface conforms closely tothe top, sides, bottom and individual toes of the foot. The methodfurther includes the step of b) adhering a first coating to sections ofthe outer surface of the fabric layer that correspond to the portions ofthe inner surface of the fabric layer that conform closely to the sides,bottom and individual toes of the foot.

According to a third aspect, the invention is an apparatus for making afootwear for a foot on a human leg having an ankle. The apparatusincludes means for forming a fabric layer having an inner surface and acorresponding outer surface, the inner surface conforming closely to thetop, sides, bottom and individual toes of the foot. The apparatus alsoincludes means for adhering a first coating to sections of the outersurface of the fabric layer that correspond to the portions of the innersurface of the fabric layer that conform closely to the sides, bottomand individual toes of the foot.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic drawing of a fabric layer of a first embodiment ofthe invention.

FIG. 2 is a schematic drawing of the first embodiment of the invention,showing the coated fabric layer.

FIG. 3 is a schematic drawing of a fabric layer of a second embodimentof the invention.

FIG. 4 is a schematic drawing of the second embodiment of the invention,showing the coated fabric layer.

FIG. 5 is a schematic drawing of a fabric layer of a third embodiment ofthe invention.

FIG. 6 is a schematic drawing of the third embodiment of the invention,showing the coated fabric layer.

FIG. 7 is a block diagram of a method for making the various embodimentof the invention.

FIG. 8 is a schematic drawing of an apparatus for making the secondembodiment of the invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT OF THE INVENTION

FIG. 1 is a schematic drawing of a fabric layer of a first embodiment ofthe invention and FIG. 2 is a schematic drawing of the first embodimentof the invention, showing the coated fabric layer. The footwear 50 isintended to be worn on the foot 51 (shown in phantom lines) of a humanleg having an ankle. The footwear 50 includes a fabric layer 52 havingan inner surface 54. An outer surface 56 of the fabric layer 52corresponds to the inner surface 54. The fabric layer 52 may be elasticand/or breathable. Preferably, the fabric layer 52 is woven from one ormore materials chosen from the class of materials including supplex,spandex, nylon, and nylon/cotton blend. Further, the fabric layer 52 caninclude an ultraviolet light inhibitor for protection of the fabriclayer 52 against sun exposure. Also, if desired, the fabric layer 52 canbe made from a sheer material that doesn't break down in water and driesquickly once wet.

The fabric layer 52 has an upper opening 53 into which the foot 51 isinserted when the footwear 50 is worn. If desired, the fabric layer 52can be high enough so that the upper opening 53 extends above the ankle55 of the human leg.

The foot 51 has a top 60, sides 62 (such as left side 62 _(L) and heelside 62 _(H), as well as the right side (not shown)), a bottom 64 andindividual toes 66 (big toe 66 _(B), little toe 66 _(P), middle toe 66_(M), and second and fourth toes 66 _(S) and 66 _(F), respectively. Theinner surface 54 conforms closely to the top 60, sides 62, bottom 64 andindividual toes 66 of the foot 51.

The footwear 50 also includes a first coating 68 which is adhered toportions of the outer surface of the fabric layer corresponding to theportions of the inner surface 54 that conform closely to the sides,bottom and individual toes of the foot 51. The first coating 68 can bemade from one or more of the form-fitting materials chosen from theclass of materials including latex, nitrile, and polyurethane.

FIG. 3 is a schematic drawing of a fabric layer of a second embodimentof the invention and FIG. 4 is a schematic drawing of the secondembodiment of the invention, showing the coated fabric layer. The samereference numerals are used in FIGS. 3 and 4 to describe featuresalready described in FIGS. 1 and 2. The footwear 50 is intended to beworn on the foot 51 (shown in phantom lines) of a human leg having anankle. The footwear 50 includes a fabric layer 52 having an innersurface 54. An outer surface 56 corresponds to the inner surface 54. Thefabric layer 52 may be elastic and/or breathable. Preferably, the fabriclayer 52 is made from one or more materials chosen from the class ofmaterials including supplex, spandex, nylon, and nylon/cotton blend.Further, the fabric layer 52 can include an ultraviolet light inhibitorfor protection of the fabric layer 52 against sun exposure. Also, ifdesired, the fabric layer 52 can be made from a sheer material thatdoesn't break down in water and dries quickly once wet.

The fabric layer 52 has an upper opening 53 into which the foot 51 isinserted when the footwear 50 is worn. If desired, the fabric layer 52can be high enough so that the upper opening 53 extends above the ankle55 of the human leg.

The foot 51 has a top 60, sides 62 (such as left side 62 _(L) and heelside 62 _(H), as well as a right side), a bottom 64 and a single toe box166 for the big toe 66 _(B) and a group toe box 167 for all of theremaining toes (little toe 66 _(P), middle toe 66 _(M), and second andfourth toes 66 _(S) and 66 _(F), respectively). The inner surface 54conforms closely to the top 60, sides 62, bottom 64 and the toe box 166of the foot 51.

The footwear 50 also includes a first coating 68 which is adhered toportions of the outer surface of the fabric layer corresponding to theportions of the inner surface 56 that conform closely to the sides,bottom and toe boxes 166 and 167 of the foot 51. The first coating 68can be made from one or more of the form-fitting materials chosen fromthe class of materials including latex, nitrile, and polyurethane.

FIG. 5 is a schematic drawing of a fabric layer of a third embodiment ofthe invention, and FIG. 6 is a schematic drawing of the third embodimentof the invention, showing the coated fabric layer. The same referencenumerals are used in FIGS. 5 and 6 to describe features alreadydescribed in FIGS. 1-4. The footwear 50 is intended to be worn on thefoot 51 (shown in phantom lines) of a human leg having an ankle. Thefootwear 50 includes a fabric layer 52 having an inner surface 54. Anouter surface 56 corresponds to the inner surface 54. The fabric layer52 may be elastic and/or breathable. Preferably, the fabric layer 52 ismade from one or more materials chosen from the class of materialsincluding supplex, spandex, nylon, and nylon/cotton blend. Further, thefabric layer 52 can include an ultraviolet light inhibitor forprotection of the fabric layer 52 against sun exposure. Also, ifdesired, the fabric layer 52 can be made from a sheer material thatdoesn't break down in water and dries quickly once wet.

The fabric layer 52 has an upper opening 53 into which the foot 51 isinserted when the footwear 50 is worn. If desired, the fabric layer 52can be high enough that the upper opening 53 just extends above theankle 55 of the human leg. If desired, the upper opening 53 of thefabric layer 52 can have a cuff 57 to help to prevent sand and the likefrom entering the footwear 50.

The foot 51 has a top 60, sides 62 (such as left side 62 _(L) and heelside 62 _(H), as well as a right side 62 _(R) (not shown)), a bottom 64and a single toe box 166 for the big toe 66 _(B), and a group toe box167 for all of the remaining toes (little toe 66 _(P), middle toe 66_(M), and second and fourth toes 66 _(S) and 66 _(F), respectively). Theinner surface 54 conforms closely to the top 60, sides 62, bottom 64 andthe toe box 166 of the foot 51.

The footwear 50 also includes a first coating 68 which is adhered tolower portions of the outer surface of the fabric layer corresponding tothe lower portions of the inner surface 56 that conform closely to thebottom 64, and the lower halves of the sides 62 and toe boxes 166 and167 of the foot 51. The first coating 68 can be made from one or more ofthe form-fitting materials chosen from the class of materials includinglatex, nitrile, and polyurethane.

FIG. 7 is a block diagram of a method 100 for making the variousembodiment of the invention. In the method, the first step is to form afabric layer (block 102). Preferably, the fabric layer is made from oneor more materials chosen from the class of materials including supplex,spandex, nylon, and nylon/cotton blend. Further, the fabric layer caninclude an ultraviolet light inhibitor for protection of the fabriclayer against sun exposure. Also, if desired, the fabric layer can bemade from a sheer material that doesn't break down in water and driesquickly once wet.

The next step in the method (block 104) is to adhere a first coating toa portion of the outer surface of the fabric layer. This step can alsoinclude immersing the fabric layer in a container of coating material tosuffuse the material through the fabric layer. If desired, the coatingmaterial may possibly have an additive to improve adhesion between thecoating material and the fabric layer. The first coating is then dried,either by exposing the first coating to an ambient condition, or byexposing the first coating to an elevated temperature or other conditionto cause the first coating to dry. The first coating can be made fromone or more of the form-fitting materials chosen from the class ofmaterials including latex, nitrile, and polyurethane.

The next step in the method (block 106) is to adhere a second coating toportions of the outer surface of the fabric layer in the same way thatthe first coating is adhered.

FIG. 8 is a schematic drawing of an apparatus for making the secondembodiment of the invention. The apparatus 200 includes an arm 202 thatsupports a foot-shaped form 204. The fabric layer 206 is placed over thefoot-shaped form 204 so that the big toe 208 _(B) of the form 204 iscontained in a toe box 210 _(B). and the other toes are contained in asingle toe box 212 or in individual toe boxes. This is signified byposition A in FIG. 8.

The apparatus 200 then lowers the arm 202 and the foot-shaped form 204into a container 214 of the coating material until the desired portionsof the outer surface of the fabric layer are immersed in the coatingmaterial. This is signified by position B in FIG. 8.

Next, the apparatus 200 raises the arm 202 and foot-shaped form 204until the foot-shaped form 204 is clear of the coating material in thecontainer 214. The apparatus 200 then allows the coating material to dryor set so that the coated fabric layer is ready for use. This issignified by position B in FIG. 8. The coated fabric layer is thenremoved from the foot-shaped form 204. Alternatively, the apparatus 200lowers the foot-shaped form 204 into the container 214 (or anothercontainer containing another coating material) so that the coatingprocess is repeated. If desired, the second coating can be caused tohave a textured surface, as will be known by those skilled in therelevant arts.

While the foregoing is a detailed description of the preferredembodiments of the invention, there are many alternative embodiments ofthe invention that would occur to those skilled in the art and which arewithin) the scope of the present invention. Accordingly, the presentinvention is to be determined by the following claims.

1. Footwear for a foot on a human leg having an ankle, comprising: afabric layer having an inner surface and a corresponding outer surface,the inner surface conforming closely to the top, sides, bottom andindividual toes of the foot; and a coating adhered to portions of theouter surface of the fabric layer corresponding to the portions of theinner surface of the fabric layer that conform closely to the sides,bottom and individual toes of the foot.
 2. The footwear of claim 1wherein the fabric layer is elastic.
 3. The footwear of claim 1 whereinthe fabric layer is breathable.
 4. The footwear of claim 1 wherein thefabric layer is made from one or more materials chosen from the class ofmaterials including supplex, spandex, nylon, and nylon/cotton blend. 5.The footwear of claim 1 wherein the fabric layer extends above theankle.
 6. The footwear of claim 1 wherein the fabric layer includes anultraviolet light inhibitor for protection against sun exposure.
 7. Thefootwear of claim 1 wherein the coating is made from one or more of theform-fitting materials chosen from the class of materials includinglatex, nitrile, and polyurethane.
 8. The footwear of claim 1 wherein thecoating has a textured surface.
 9. A method for making a footwear for afoot on a human leg having an ankle, comprising the steps of: a) forminga fabric layer having an inner surface and a corresponding outersurface, the inner surface conforming closely to the top, sides, bottomand individual toes of the foot; and b) adhering a first coating toportions of the outer surface of the fabric layer corresponding to theportions of the inner surface of the fabric layer that conform closelyto the sides, bottom and individual toes of the foot.
 10. The method ofclaim 9, wherein step b) includes immersing the portions of the outersurface of the fabric layer corresponding to the portions of the innersurface of the fabric layer that conform closely to the sides, bottomand individual toes of the foot in a container filled with the materialcomposing the first coating.
 11. The method of claim 10, wherein step b)further includes adding a chemical agent to the material composing thefirst coating to insure adhesion of the first coating to the outersurface of the fabric layer corresponding to the portions of the innersurface of the fabric layer that conform closely to the sides, bottomand individual toes of the foot in a container filled with the materialcomposing the first coating.
 12. The method of claim 9, furtherincluding the step of: c) adhering a second coating over the firstcoating.
 14. The method of claim 9, wherein step c) includes causing thesecond coating to have a textured surface.
 15. The method of claim 9,wherein step b) includes suffusing the first coating through the fabriclayer.
 16. The method of claim 9, wherein step b) includes drying thefirst coating.
 17. An apparatus for making a footwear for a foot on ahuman leg having an ankle, comprising: means for forming a fabric layerhaving an inner surface and a corresponding outer surface, the innersurface conforming closely to the top, sides, bottom and individual toesof the foot; and means for adhering a first coating to portions of theouter surface of the fabric layer corresponding to the portions of theinner surface of the fabric layer that conform closely to the sides,bottom and individual toes of the foot.
 18. The apparatus of claim 17,wherein the means for adhering includes means for immersing the portionsof the outer surface of the fabric layer corresponding to the portionsof the inner surface of the fabric layer that conform closely to thesides, bottom and individual toes of the foot in a container filled withthe material composing the first coating.
 19. The apparatus of claim 18,wherein the means for adhering further includes means for adding achemical agent to the material composing the coating to insure adhesionof the first coating to the outer surface of the fabric layercorresponding to the portions of the inner surface of the fabric layerthat conform closely to the sides, bottom and individual toes of thefoot in a container filled with the material composing the firstcoating.
 20. The apparatus of claim 17, further including means foradhering a second coating over the first coating.
 21. The apparatus ofclaim 17, wherein the means for adhering includes means for suffusingthe first coating through the fabric layer.
 22. The apparatus of claim17, wherein the means for adhering includes means for drying the firstcoating.